First Solar, Inc.

Stacy Ann Black

Scott Daniel Feldman-Peabody

Mark Jeffrey Pavol

Max William Reed

An apparatus and related process are provided for vapor deposition of a sublimated source material as a thin film on a photovoltaic (PV) module substrate. A deposition head is configured for sublimating a source material supplied thereto. The sublimated source material condenses onto a transport conveyor disposed below the deposition head. A substrate conveyor is disposed below the transport conveyor and conveys substrates in a conveyance path through the apparatus such that an upper surface of the substrates is opposite from and spaced below a lower leg of the transport conveyor. A heat source is configured adjacent the lower leg of the transport conveyor. The source material plated onto the transport conveyor is sublimated along the lower leg and condenses onto to the upper surface of substrates conveyed by the substrate conveyor.

Vapor deposition apparatus and process for continuous indirect deposition of a thin film layer on a substrate

Photovoltaic devices are provided that include a thin film stack (of a plurality of photovoltaic cells connected in series to each other) on a transparent substrate, a first busbar electrically connected to the first terminal cell, and a second busbar electrically connected to the second terminal cell. An encapsulation substrate is on the plurality of thin film layers and defines a first connection aperture positioned over the first busbar and a second connection aperture positioned over the second bus bar. A first electrical connector is positioned on the encapsulation substrate and is electrically connected to the first busbar through the first connection aperture, and a second electrical connector is positioned on the encapsulation substrate and is electrically connected to the second busbar through the second connection aperture. Solar arrays and kits are also provided that include such photovoltaic devices and a connection cable.

Integrated power connectors for PV modules and their methods of manufacture

A method for vapor deposition of a sublimated source material, such as CdTe, onto substrates in a continuous, non-stop manner through the apparatus is provided. The sublimated source material moves through a distribution plate and deposits onto the upper surface of the substrates as they are conveyed through the deposition area. The substrates move into and out of the deposition area through entry and exit slots that are defined by transversely extending entrance and exit seals. The seals are disposed at a gap distance above the upper surface of the substrates that is less than the distance or spacing between the upper surface of the substrates and the distribution plate. The seals have a ratio of longitudinal length (in the direction of conveyance of the substrates) to gap distance of from about 10:1 to about 100:1.

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Longmont, CO, United States of America

Stacy Ann Black